Bedspring and method of making the same

ABSTRACT

A bedspring includes a plurality of spaced parallel longitudinal cross wires and a plurality of spaced parallel transverse cross wires connected to each other at respective cross points and having the ends thereof connected to a frame. The cross wires together form an intersecting grid-like array. Coil springs each have a coil turn at one end thereof which is positioned in a space in the grid-like array of cross wires. Each coil turn is interposed between one pair of transversely extending cross wires and one pair of longitudinally extending cross wires which together form the respective space. The longitudinal extending cross wires include offset portions or indentations which receive or accommodate opposite peripheral portions of a respective coil turn while the latter abuts against the transverse cross wires. The offset portions in the longitudinal cross wires maintain the coil turns in abutment with the transverse cross wires without the application of excessive compressive forces on the coil turns and without the generation of excessive internal stresses in the bedspring after the latter is assembled. A method of forming the bedspring in accordance with the present invention is also described.

United States Patent [191 Anonauer BEDSPRING AND METHOD OF MAKING THE SAME [75] Inventor: lrwin Anonauer,'0ceanside. L. 1..

[73] Assignee: Spring Associates, Inc., Brooklyn.

[22] Filed: May 14, 1973 [21] Appl. No.: 359,988

Primary Examiner-James C. Mitchell Attorney, Agent, or FirmFreidman & Goodman [57] ABSTRACT A bedspring includes a plurality of spaced parallel 1on- 1 Feb. 11,1975

gitudinal cross wires and a plurality of spaced parallel transverse cross wires connected to each other at respective cross points and having the ends thereof connected to a frame. The cross wires together form an intersecting grid-like array. Coil springs each have a coil turn at one end thereof which is positioned in a space in the grid-like array of cross wires. Each coil turn is interposed between one pair of transversely extending cross wires and one pair of longitudinally extending cross wires which together form the respective space. The longitudinal extending cross wires include offset portions or indentations which receive or accommodate opposite peripheral portions of a respective coil turn while the latter abuts against the transverse cross wires. The offset portions in the longitudinal cross wires maintain the coil turns in abutment with the transverse cross wires without the application of excessive compressive forces on the coil turns and without the generation of excessive internal stresses in the bedspring after the latter is assembled. A method of forming the bedspring in accordance with the present invention is also described.

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SHEET 2 BF 2 BEDSPRING AND METHOD OF MAKING THE SAME BACKGROUND OF THE INVENTION The present invention generally relates to bedsprings, and more particularly to a bedspring having at least one set of parallel cross wires provided with offset portions which receive coil spring end turns. in the assembled state of the bedspring, without the generation of excessive stresses between the coil springs and the cross wires or between the cross wires themselves. The invention also relates to the method of forming such a bedspring.

As is well known, there are countless varieties of coil spring assemblies or bedsprings which are arranged as a spring base, such as spring bed bottoms, each having associated therewith a respective method of construction. In this respect, bedsprings of conventional nature generally include a plurality of equally spaced longitu dinally extending metallic rods or cross wires and a plurality of equally spaced transversely extending metallic rods or cross wires respectively intersecting one another to form a grid-like array. Coil springs of generally helical nature are fastened to the cross wires such as by clamps,-wire twists, staples or other suitable securing means well known to those skilled in the art. Such connection of coil springs to associated pairs of longitutlinally and transversely extending metallic rods is performed either manually or by machine.

Alternately, the helical springs are secured by providing additional longitudinally and transversely extendng metallic rods or cross wires which are interposed between the primary longitudinally and transversely extending metallic cross wires and interlaced through end turns of the helical springs for fastening or otherwise securing the latter into a fixed assembly.

Still another variety of bedsprings utilizes a feature of interlacing a helical end turn portion of each of the coil bedsprings successively over and under associated pairs of longitudinally and transversely extending metallic rods or cross wires.

The conventional bedsprings are generally complex both with regard to the required materials of construction and to the associated methods of construction. Thereby, the known bedsprings are difficult, time consuming, and expensive to manufacture.

A bedspring or spring base and method of forming the same intended to overcome the above described disadvantages is described in copcnding application Ser. No. 214,773, assigned to the ASsignee ofthe present application. In the copcnding application, a bedspring is described which comprises an intersecting grid-like array of transversely and longitudinally extending metallic rods or cross wires which are welded to one another at mutually intersecting portions. A plurality of springs are connected to the grid-like array. Each of the springs is provided with a closed, generally circular end turn which is wedged under pressure and restrained against lateral displacement by a pair of Iongitudinally extending metallic rods biasing thereagainst in one direction and an associated pair of transversely extending metallic rods biasing thereagainst in a generally opposite direction.

Although the bedspring described in Application Ser. No. 214,773 overcomes the above described disadvantages of similar bedsprings of the prior art, it has the disadvantage that the rods or cross wires must be flexed to wedge the coil spring end turns as when the cross wires are welded to each other at respective crossing points. Consequently, at least one set of cross wires must be flexed prior to welding. Also, after the bedspring is assembles, stresses exist at the welds, the stresses being such as to revert the flexed cross wires back to their normal linear conditions.

SUMMARY OF THE INVENTION Accordingly. it is an object of the present invention to provide a bedspring which does not have the disadvantages associated with similar spring arrangements known in the prior art.

It is another object of the present invention to provide a bedspring of the type under discussion which is simple in construction and economical to manufacture.

It is still another object of the present invention to provide a bedspring as above described which is especially adapted for mass production.

It is yet another object of the present invention to provide a bedspring which includes at least some cross wires provided with indentations or offsets which are adapted to receive peripheral portions of coil spring end turns.

It is a further object of the present invention to provide a bedspring wherein the cross wires need not be flexed or placed under stress prior to welding respec tive transversely disposed cross wires to each other.

It is still a further object of the present invention to provide a bedspring which, when assembled. does not exhibit internal stresses which tend to separate the welded cross wires from one another.

It is yet a further object of the present invention to provide a method of forming a bedspring as above described.

In order to achieve the above objects, as well as others which will become apparent hereafter, a bedspring in accordance with the present invention comprises a plurality of spaced elongate longitudinally extending members. A plurality of spaced elongate transversely extending members are also provided and connecting means are provided for connecting said transversely extending members to said longitudinally extending members to form an intersecting grid-like array defining a plurality of spaces. Frame means is provided for supporting said grid-like array of members. A plurality of coil springs are provided each having a coil turn at one end thereof positioned in a space in said grid-like array of members. Each coil turn is interposed between one pair of transversely extending members and one pair of longitudinally extending members together forming the respective space. At least one of said pairs of members includes preformed offset means for receiving opposite peripheral portions of said respective coil turn while the latter abuts against the other pair of said members. In this manner, each coil spring is fixed in position in said grid-like array and is prevented from separating from the bedspring members.

In accordance with one presently preferred embodiment, said preformed offset means comprises indentations in said one pair of members or offset portions in said one pair of members substantially parallel to the latter and offset from the longitudinal extent of the latter a predetermined distance. According to one embodiment of the offset portions, these are offset a predetermined distance substantially equal to the cross sectional diameter of said coil turn. According to another embodiment of the offset portion, the offset portion is offset a predetermined distance slightly smaller than the cross sectional diameter of the coil turn. In this manner, said coil turn abuts against said members without clearance.

According to one feature of the present invention, wherein each member in said one pair of members has a length portion coextensive with said coil turn, each preformed offset means comprises an offset portion which includes at least a respective coextensive length portion. According to a variation of this feature. each offset portion extends substantially between two adjacent elongate members of said other pair of members.

The method of forming a bedspring in accordance with the present invention comprises the step of forming a bedspring frame. A first plurality of elongate members are then connected to said frame in parallel relation to each other. A plurality of coil springs are then positioned in spaced relation in abutment against said elongate members. A second plurality of elongate members are formed each having preformed offset means therealong spaced from each other distances equal to the distances between adjacent coil springs. Said second plurality of elongate members are positioned in parallel relation to each other in a transverse direction to the direction of said first plurality of elongate members with each preformed offset means receiving a peripheral portion of a respective coil spring. The ends of said second plurality of elongate members are then connected to said frame. Said first and second elongate members are then connected to each other at respective crossing points to thereby fix each coil spring between said first plurality of elongate members and respective ones of said preformed offset means.

According to a feature of the present method, the step of forming said second plurality of elongate members comprises forming a preformed offset portion on each member of said second plurality of elongate members in spaced relation from a respective member of said first plurality of elongate members a distance substantially equal to the cross sectional diameter of said coil turn.

According to another feature of the method, the step of forming said second plurality of elongate members comprises the step of forming a preformed offset por tion on each member of said second plurality of elongate members, the length of each offset portion being substantially equal to the spacing between adjacent members of said first plurality of elongate members.

BRIEF DESCRIPTION OF THE DRAWINGS With the above and additional objects and advantages in view, as well hereinafter appear, this invention comprises the devices, combinations and arrangements of parts hereinafter described and illustrated in the accompanying drawings of a preferred embodiment in which:

FIG. 1 is a bottom plan view of a corner of a bedspring in accordance with the present invention, show ing one coil turn fixed in position by one pair oflongitudinal cross wires and one pair of transverse cross wires;

FIG. 2 is a side elevational view of the bedspring corner shown in FIG. 1;

FIG. 3 is a bottom plan view ofa section of the bedspring in accordance with the present invention, showing the bedspring in an intermediate stage of assembly;

and

FIG. 4 is a bottom plan view of a section of the bedspring shown in FIG. 3, showing the bedspring in a completed form.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the Figures, in which similar or identical parts have been designated by the same reference numerals, and first referring to FIG. I, an enlarged corner portion of a bedspring 10 in accordance with the present invention is illustrated. The bedspring 10 generally comprises a bedspring frame 12 which is generally rectangular in configuration. Accordingly, the frame 12 includes a frame rod or side wire 14 generally defining a transverse direction of the frame and a frame rod or side wire 16 which generally defines a longitudinal direction ofthe frame. A plurality or series of spaced elongate transversely extending members in the form of transverse cross wires 18 extend from the frame side wires 16 and are connected to the latter at respective ends by means of welds 20.

A coil spring 30, of conventional design, includes a coil turn 32 at one end thereof and a helical portion 34 extending upwardly therefrom. The diameter of the coil turn 32 is somewhat larger than the spacing between adjacent transverse cross wires 18 so that peripheral portions 32c, 32d project beyond the two adjacent transverse cross wires against which they abut.

A plurality or series of spaced elongate longitudinally extending members in the form of longitudinal cross wires 40 extend from the frame side wire 14 and are connected to the latter at their respective ends by means of welds 42. Connecting means in the form, for example, of welds connect the transverse cross wires 18 to the longitudinal cross wires 40 at respective crosspoints 46 to form an intersecting grid-like array which define a plurality of spaces 43.

It will be noted that the transverse cross wire 18 adjacent to the side wire 16 and the longitudinal cross wire 40 adjacent to the side wire 14 meet and overlap at the frame corner formed by the side wires and are welded to the latter. Such construction more evenly distributes the load placed on the coil turn 32.

The coil spring 32 is positioned centrally in a space 43 of the grid-like array of members. The coil turn 32 is interposed between one pair of transverse cross wires 18 and a pair of longitudinal cross wires 40.

Thus far, the bedspring 10 is substantially the same as that described in copending US. application Ser. No. 214,773. Referring to FIGS. 1 and 2, an important feature of the present invention comprises the provision of preformed offsets 44 in the longitudinal cross wires 40 for receiving opposite peripheral portions 32a, 32b, of the respective coil turn 32 while the latter abuts against the pair of transverse cross wires 18. In this manner, each coil spring is fixed or locked in position within the grid-like array and is prevented from separating from the bedspring cross wires.

The preformed offsets 44 may be in the form of indentations or offset portions in the longitudinal cross wires 40 substantially parallel to the latter and offset from the longitudinal extent therof a predetermined distance which, in the presently preferred embodiment, substantially equals the cross sectional diameter of the coil turn 32. In this manner, the offset portions 44 are sufficiently elevated, as viewed in FIG. 2, above the transverse cross wires 18 subsequent to the formation of the grid-like array so as to provide spaces which can receive the opposite peripheral portions 32a, 32b, while the coil turn 32 substantially lies in a plane parallel to the general plane of the bedspring 10.

According to a variation of the above described offset portions 44, the latter are offset above the longitudinal extent of the cross wires 40 a distance slightly smaller than the cross sectional diameter of the coil turn 32. In this manner, the coil turn is fixed between the cross wires 18 and the offset portions 44 without clearance.

As best illustrated in FIGS. 1 and 2, each longitudinal cross wire 40 has a length portion thereof coextensive with a peripheral portion of the end turn of the coil. According to a slight modification, each offset portion 44 extends substantially between two adjacent transverse cross wires 18.

Of importance in the present construction is the fact that the coil turn 32 remains, after assembled in the bedspring 10, in a substantially flat plane. Accordingly, the coil turn 32 does not exert any forces on the cross wires forming the grid-like array. If the indentations or offset portions 44 are sufficiently long and sufficiently offset above the respective transverse cross wires 18, the cross wires 18, 40 similarly do not exert stressing forces upon the coil turn 32. Consequently, the construction illustrated in FIGS. 1 and 2 results in substantially passive containment or retention of the coil turns 32 by the cross wires.

The indentations or offset portions 44 are formed by bending the longitudinal wires 40 along their length. In FIG. 2, a bent portion 44a is shown at one end of the offset portion while another bent portion 44b is shown at the other end of the offset portion. Clearly, the offset portion 44 may so be selected so as to either totally lock the coil turns 32 against movement or may be selected to provide limited movement of the coil turns. Thus, by selecting the length of the offset portion 44 to be substantially equal to that length of the longitudinal cross wires which are coextensive with the coil turn, reception of the peripheral portions 32a, 3212 may be had in the spaces formed by the indentations or offset portions with little clearance. On the other hand, by enlarging the length dimensions of the indentations 44, more movement of the coil turn 32 may be obtained.

The cross wires 18 and 40 are respectively connected such as by welding at cross points 46. Since the coil turn does not exert any forces on the cross'wires and vice versa, the stresses placed at the weld formed at the cross points 46 are minimal. Such construction assures maximum reliability and long lifetime.

Although the indentations or offset portions 44 have been illustrated and described in connection with the longitudinal cross wires 40, it should be equally clear that such indentations or offset portions may similarly be provided in the transverse cross wires or in both cross wires forming the grid-like array.

The method in accordance with the present invention will now be described in relation to FIGS. 3 and 4. To construct a bedspring as shown in H65. 1 and 2, a plurality of transverse cross wires 18 are connected to the frame side wires 16 by means of welds 20. The transverse wires 18 are substantially parallel with respect to each other and to the frame side wire 14. Each successive two transverse cross wires 18 form a pair of such cross wires for the purpose of supporting a plurality of coil springs 30. A plurality of coil springs 30 are spaced along the transverse cross wires 18 along the length of the latter. For the specific embodiment illustrated, a plurality of longitudinal cross wires 40 are formed each having preformed offset portions spaced from each other therealong distances equal to the distances between adjacent coil springs in a longitudinal direction. The longitudinal cross wires 40 are then placed in parallel relation to each other in a longitudinal direction and so arranged so as to receive peripheral portions of respective coil springs. More particularly. the transverse cross wires 18 and the longitudinal cross wires 40 are so arranged so as to form a grid-like array wherein respective peripheral portions 32c, 32! each abut against respective transverse cross wires 18 while respective peripheral portions 32a, 32b are received in spaces formed by the indentations or offset portions 44.

It is to be noted that when the transverse cross wires 18 are now welded to the longitudinal cross wires 40 at respective cross points 46, neither the longitudinal nor the transverse cross wires must be bent or flexed in order to bring the two wires together or join the two cross wires at the cross points 46 for the purpose of welding. As soon as the longitudinal cross wires 40 are disposed above the transverse cross wires 18 as shown in FIG. 4, wherein the peripheral portions 32a, 3212 respectively project or are received in the spaces formed by the indentation or offset portions 44, the longitudinal cross wires 40 meet or abut against each of the transverse cross wires 18 along the entire longitudinal length of the frame 12. It now becomes an extremely simple matter to weld the respective cross wires at each of the adjoining or abutting cross wire portions or cross points 46.

The novel construction in accordance with the present invention obviates the creation of internal stresses in the bedspring 10 when no external forces are applied to the bedspring. Thus, in the steady state condition of the bedspring, wherein no external forces are applied thereto, there is created a substantially passive or nearly passive engagement between the cross wires and the coil turns 32 wherein the latter are nevertheless fixed or locked in position.

The bedspring in accordance with the present invention facilitates construction thereof and provides a more reliable bedspring due to the decrease in likelihood of separation caused by internal stresses which permanently or continuously act even in the absence of external forces as is the case with many prior art bedsprings.

Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to a preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention.

What is claimed is:

l. A bedspring comprising a series of spaced elongate transversely extending members arranged substantially in a common plane; a series of spaced elongate longitudinally extending members disposed on one side of said plane and fixedly connected to said transversely extending members to form an intersecting grid-like array defining a plurality of spaces; at least one of said series of members being provided with indentations recessed in a direction away from the other of said series of members; a frame extending around said grid-like array, the free ends of said elongate members being connected to said frame and being supported by the latter; a plurality of coil springs each having a coil turn at one end thereof positioned coextensively with a space of said grid-like array of members, each end coil turn having dimensions greater than the spacing between adjacent longitudinal members and being interposed between one pair of transversely extending members and one pair of longitudinally extending members to position opposite peripheral portions of each end coil turn within respective indentations, whereby each coil spring is fixed in position in said grid-like array and is prevented from separating from the bedspring members.

2. A bedspring as defined in claim 1, wherein said indentations comprises offset portions in said one pair of members substantially parallel to the latter and offset from the longitudinal extent of the latter a predetermined distance.

3. A bedspring as defined in claim 2, wherein said predetermined distance substantially equals the cross sectional diameter of said coil turn.

4. A bedspring as defined in claim 2, wherein said predetermined distance is slightly smaller than the cross sectional diameter of said coil turn, whereby said coil turn abuts against said members without clearance.

5. A bedspring as defined in claim 1, wherein each member in said one pair of members has a length portion coextensive with said coil turn, each indentations comprising an offset portion which includes at least a respective coextensive length portion.

6. A bedspring as defined in claim 5, wherein each offset portion extends substantially between two adjacent elongate members of said other pair of members.

7. A bedspring as defined in claim 1, wherein said frame comprises an open rectangular frame having corner portions, and wherein respective ones of said longitudinally and transversely extending cross members adjacent to said frame meet and overlap adjacent to respective corner portions and are connected to the latter. 

1. A bedspring comprising a series of spaced elongate transversely extending members arranged substantially in a common plane; a series of spaced elongate longitudinally extending members disposed on one side of said plane and fixedly connected to said transversely extending members to form an intersecting grid-like array defining a plurality of spaces; at least one of said series of members being provided with indentations recessed in a direction away from the other of said series of members; a frame extending around said grid-like array, the free ends of said elongate members being connected to said frame and being supported by the latter; a plurality of coil springs each having a coil turn at one end thereof positioned coextensively with a space of said grid-like array of members, each end coil turn having dimensions greater than the spacing between adjacent longitudinal members and being interposed between one pair of transversely extending members and one pair of longitudinally extending members to position opposite peripheral portions of each end coil turn within respective indentations, whereby each coil spring is fixed in position in said grid-like array and is prevented from separating from the bedspring members.
 2. A bedspring as defined in claim 1, wherein said indentations comprises offset portions in said one pair of members substantially parallel to the latter and offset from the longitudinal extent of the latter a predetermined distance.
 3. A bedspring as defined in claim 2, wherein said predetermined distance substantially equals the cross sectional diameter of said coil turn.
 4. A bedspring as defined in claim 2, wherein said predetermined distance is slightly smaller than the cross sectional diameter of said coil turn, whereby said coil turn abuts against said members without clearance.
 5. A bedspring as defined in claim 1, wherein each member in said one pair of members has a length portion coextensive with said coil turn, each indentations comprising an offset portion which includes at least a respective coextensive length portion.
 6. A bedspring as defined in claim 5, wherein each offset portion extends substantially between two adjacent elongAte members of said other pair of members.
 7. A bedspring as defined in claim 1, wherein said frame comprises an open rectangular frame having corner portions, and wherein respective ones of said longitudinally and transversely extending cross members adjacent to said frame meet and overlap adjacent to respective corner portions and are connected to the latter. 